Introduction to Nondestructive Testing

Outline
Introduction to NDT Overview of Six Most Common NDT Methods Selected Applications

Definition of NDT
The use of noninvasive techniques to determine the integrity of a material, component or structure or quantitatively measure some characteristic of an object.
i.e. Inspect or measure without doing harm.

Methods of NDT
Visual

What are Some Uses of NDE Methods?

Flaw Detection and Evaluation

Leak Detection
Location Determination Dimensional Measurements
Fluorescent penetrant indication

Structure and Microstructure Characterization

Estimation of Mechanical and Physical Properties Stress (Strain) and Dynamic Response Measurements Material Sorting and Chemical Composition Determination

When are NDE Methods Used?

There are NDE application at almost any stage in the production or life cycle of a component. To assist in product development To screen or sort incoming materials To monitor, improve or control manufacturing processes To verify proper processing such as heat treating To verify proper assembly To inspect for in-service damage

Six Most Common NDT Methods

Visual Liquid Penetrant Magnetic Ultrasonic Eddy Current X-ray

Visual Inspection
Most basic and common inspection method. Tools include fiberscopes, borescopes, magnifying glasses and mirrors. Portable video inspection unit with zoom allows inspection of large tanks and vessels, railroad tank cars, sewer lines. Robotic crawlers permit observation in hazardous or tight areas, such as air ducts, reactors, pipelines.

Liquid Penetrant Inspection

A liquid with high surface wetting characteristics is applied to the surface of the part and allowed time to seep into surface breaking defects. The excess liquid is removed from the surface of the part. A developer (powder) is applied to pull the trapped penetrant out the defect and spread it on the surface where it can be seen. Visual inspection is the final step in the process. The penetrant used is often loaded with a fluorescent dye and the inspection is done under UV light to increase test sensitivity.

Magnetic Particle Inspection

The part is magnetized. Finely milled iron particles coated with a dye pigment are then applied to the specimen. These particles are attracted to magnetic flux leakage fields and will cluster to form an indication directly over the discontinuity. This indication can be visually detected under proper lighting conditions.

Magnetic Particle Crack Indications

Radiography
The radiation used in radiography testing is a higher energy (shorter wavelength) version of the electromagnetic waves that we see as visible light. The radiation can come from an X-ray generator or a radioactive source.
High Electrical Potential Electrons + -

X-ray Generator or Radioactive Source Creates Radiation

Radiation Penetrate the Sample

Exposure Recording Device

Film Radiography
The part is placed between the radiation source and a piece of film. The part will stop some of the radiation. Thicker and more dense area will stop more of the radiation. The film darkness (density) will vary with the amount of radiation reaching the film through the test object. = less exposure

X-ray film

= more exposure
Top view of developed film

Radiographic Images

Eddy Current Testing

Coil's magnetic field

Coil

Eddy current's magnetic field

Eddy currents Conductive material

Eddy Current Testing

Eddy current testing is particularly well suited for detecting surface cracks but can also be used to make electrical conductivity and coating thickness measurements. Here a small surface probe is scanned over the part surface in an attempt to detect a crack.

Ultrasonic Inspection (Pulse-Echo)

High frequency sound waves are introduced into a material and they are reflected back from surfaces or flaws. Reflected sound energy is displayed versus time, and inspector can visualize a cross section of the specimen f showing the depth of features that reflect sound.
initial pulse

crack echo

back surface echo

crack
0 2 4 6 8 10

plate

Oscilloscope, or flaw detector screen

Ultrasonic Imaging
High resolution images can be produced by plotting signal strength or time-of-flight using a computercontrolled scanning system.

Gray scale image produced using the sound reflected from the front surface of the coin

Gray scale image produced using the sound reflected from the back surface of the coin (inspected from heads side)

Common Application of NDT

Inspection of Raw Products Inspection Following Secondary Processing In-Services Damage Inspection

Inspection of Raw Products

Forgings, Castings, Extrusions, etc.

Inspection Following Secondary Processing

Machining Welding Grinding Heat treating Plating etc.

Inspection For In-Service Damage

Cracking Corrosion Erosion/Wear Heat Damage etc.

Power Plant Inspection

Periodically, power plants are shutdown for inspection. Inspectors feed eddy current probes into heat exchanger tubes to check for corrosion damage.

Pipe with damage

Probe
Signals produced by various amounts of corrosion thinning.

Wire Rope Inspection

Electromagnetic devices and visual inspections are used to find broken wires and other damage to the wire rope that is used in chairlifts, cranes and other lifting devices.

Storage Tank Inspection

Robotic crawlers use ultrasound to inspect the walls of large above ground tanks for signs of thinning due to corrosion. Cameras on long articulating arms are used to inspect underground storage tanks for damage.

Aircraft Inspection
Nondestructive testing is used extensively during the manufacturing of aircraft. NDT is also used to find cracks and corrosion damage during operation of the aircraft. A fatigue crack that started at the site of a lightning strike is shown below.

Jet Engine Inspection

Aircraft engines are overhauled after being in service for a period of time. They are completely disassembled, cleaned, inspected and then reassembled. Fluorescent penetrant inspection is used to check many of the parts for cracking.

Crash of United Flight 232 Sioux City, Iowa, July 19, 1989
A defect that went undetected in an engine disk was responsible for the crash of United Flight 232.

Pressure Vessel Inspection

The failure of a pressure vessel can result in the rapid release of a large amount of energy. To protect against this dangerous event, the tanks are inspected using radiography and ultrasonic testing.

Rail Inspection
Special cars are used to inspect thousands of miles of rail to find cracks that could lead to a derailment.

Bridge Inspection
The US has 578,000 highway bridges. Corrosion, cracking and other damage can all affect a bridges performance. The collapse of the Silver Bridge in 1967 resulted in loss of 47 lives. Bridges get a visual inspection about every 2 years.

Some bridges are fitted with acoustic emission sensors that listen for sounds of cracks growing.

Pipeline Inspection
NDT is used to inspect pipelines to prevent leaks that could damage the environment. Visual inspection, radiography and electromagnetic testing are some of the NDT methods used.

Remote visual inspection using a robotic crawler.

Magnetic flux leakage inspection. This device, known as a pig, is placed in the pipeline and collects data on the condition of the pipe as it is pushed along by whatever is being transported.

Radiography of weld joints.

Special Measurements
Boeing employees in Philadelphia were given the privilege of evaluating the Liberty Bell for damage using NDT techniques. Eddy current methods were used to measure the electrical conductivity of the Bell's bronze casing at a various points to evaluate its uniformity.

For More Information on NDT

The Collaboration for NDT Education www.ndt-ed.org

The American Society for Nondestructive Testing www.asnt.org